Wax-coated cheese

ABSTRACT

A wax-coated cheese comprising a cheese portion, a first inner wax layer covering the cheese portion, a second outer wax layer covering the first inner wax layer, a tear strip between the first inner and second outer wax layers covering selected parts of the first inner wax layer and comprising at least one portion which protrudes from the first inner and second outer wax layers and comprising an adhesive layer for adhering the tear strip to the first inner wax layer. Also disclosed is a corresponding packaging system and a packaging process.

FIELD OF THE INVENTION

The present invention relates to wax-coated cheese, a newcoating/opening system and a process for making same.

DESCRIPTION OF THE PRIOR ART

In many consumer packaging applications, it is important to prevent airor water or the like from passing out of or into the package containingcertain products. This is particularly true with respect to cheesepackages for which the contained product must be kept in a controlledenvironment to prevent spoilage and deterioration. In order to preservethe integrity and safety of such a cheese product contained within sucha package, the periphery of the package may be hermetically sealed.

It is known from various prior art documents to protect cheese againstsurface deterioration as caused principally by the formation of mold, bymeans of a surrounding film consisting of an impermeable flexiblecoating material such as wax, covering the cheese to be protected and inwhich is embedded a strip of which one or two ends protrude from theouter surface of the surrounding envelope, thereby enabling the cheeseto be disengaged from the envelope after the strip has been removed.

Such cheese products and processes for making them are for exampledescribed in French Patent No. 1,388,048.

The entire packaging process in which the cheese is covered with theprotecting wax layer and with the tear strip must take place under thestrict environmental conditions required to extend shelf life, which iscomplicated and expensive.

There is a need for a system and process for packaging cheese in a lesscomplicated and less expensive manner.

SUMMARY OF THE INVENTION

One embodiment of the invention comprises:

-   -   (a) a cheese portion,    -   (b) a first inner wax layer covering the cheese portion,    -   (c) a second outer wax layer covering the first inner layer,    -   (d) a tear strip between the first inner and second outer wax        layers covering selected parts of the first inner wax layer and        comprising a portion which protrudes from the first inner and        second outer wax layers and comprising an adhesive layer for        adhering the tear strip to the first inner layer.

In preferred embodiments of the invention the first inner wax layer isuncolored and/or the second outer wax layer is colored.

In a further preferred embodiment of the invention the tear stripcomprises a plurality of holes throughout through which the first innerand second outer wax layers are firmly connected.

The cheese may be natural cheese, processed cheese, cream or freshcheese or any other type of cheese. The preferred cheese is processedcheese.

The cheese portion may have any desired form and is preferablytriangular.

The invention also may provide a corresponding packaging system usefulfor packaging a processed cheese portion.

In one preferred embodiment of this invention, the tear strip surroundsall three side walls of a generally triangular processed cheese portionand has one protruding portion.

In another preferred embodiment, the tear strip is provided at the twoelongated side walls of the triangular processed cheese portion and hasone or two protruding portions.

In still another embodiment, the tear strip is provided at the top andat one elongated side wall of the processed cheese portion and has oneprotruding portion.

Furthermore, there is provided a process for packaging a cheese portionthat may comprise

-   -   (a) providing a cheese portion with a first inner wax layer,    -   (b) placing a tear strip with its adhesive layer over selected        parts of the first inner wax layer wherein the tear strip        comprises a portion which protrudes from the first inner wax        layer,    -   (c) applying a second outer wax layer onto the first inner wax        layer and the tear strip.

In a preferred embodiment of the invention the tear strip has aplurality of holes throughout and step (c) is carried out underconditions which allow the first inner and second outer wax layers tomelt together and form a firm connection through the holes of the tearstrip.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is perspective side view of a triangular cheese portion coveredwith a first inner wax layer which is surrounded on its side walls witha preferred tear strip having a plurality of holes and one protrudingtear strip portion;

FIG. 1 b is a perspective side view of the embodiment of FIG. 1 a whichis covered with a second outer wax layer;

FIG. 1 c is a perspective side view of the embodiment of FIG. 1 b whichis opened at two sides after tearing the tear strip;

FIGS. 2 a to 2 c are perspective side views of another embodimentcorresponding to FIG. 1 a to 1 c with a preferred tear strip on the twoelongated side walls of the cheese portion having a plurality of holesand one protruding tear strip portion;

FIGS. 3 a to 3 c are perspective side views of another embodiment of thepresent invention with a preferred tear strip on top and on oneelongated side wall of the processed cheese portion having a pluralityof holes and one protruding tear strip portion.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to cheese and a new packaging system whichis useful for packaging cheese. The key advantage of this new packagingsystem is the avoidance of carrying out the entire packaging processunder the strict environmental conditions required to extend shelf life.

The cheese portions are simply covered under those strict environmentalconditions with one preferably uncolored wax layer and all of theremaining packaging steps, i.e., fixing the tear strip onto the firstinner wax layer and applying the second outer wax layer, can then beeffected under less strict environmental conditions, which is mostadvantageous.

Preferred embodiments of the invention will now be explained withrespect to the drawings.

The cheese may be any known type of cheese, e.g., natural cheese,processed cheese or cream or fresh cheese. Preferably it is processedcheese.

As mentioned above, the cheese portion to be packaged can have anydesired form but is preferably triangular.

FIG. 1 a shows in a perspective view a cheese portion 5 which is coveredwith a first inner wax layer 1 and which is surrounded on all of itsthree side walls with a tear strip 2 which has a portion 3 whichprotrudes from the tip of the cheese portion 5 and which has as apreferred embodiment a plurality of holes 6 along its length. The tearstrip 2 has been fixed onto the first inner wax layer 1 by means of anadhesive.

FIG. 1 b shows the embodiment of FIG. 1 a which has been covered with asecond outer wax layer 4. The application of the second outer wax layer4 is carried out under conditions which lead to a melting together ofthe two wax layers 1, 4 so that they can easily be separated from thecheese portion 5. The two wax layers 1, 4 also melt together through theholes 6 of the tear strip 2 so that the tear strip is firmly embeddedbetween the two wax layers 1,4. This allows an accurate opening of theouter wax layer 4 along the lines of the tear strip 2. The same appliesto the first inner wax layer 1 which firmly adheres to the tear strip 2by means of the adhesive with which it has been fixed onto the firstinner wax layer 1 and by means of the holes 6 of the tear strip 2through which the two wax layers 1, 4 have been melted together. Asmentioned above, the holes in the tear strip relate to a preferredembodiment of the invention, and are not necessary to carry out theinvention. Normally, the adhesive layer on the tear strip is sufficientto form a firm connection to the first inner wax layer 1.

FIG. 1 c shows the same embodiment which has been opened by tearing awaythe tear strip 2 from two sides of the triangular cheese portions. Itcan be seen that the inner side of the tear strip 2 is covered with thefirst inner wax layer 1 which has been torn away from the cheese portion5 and the tear strip 2 can be easily and completely separated by furthertearing the tear strip 2 from the third side wall of the cheese portion5. Finally, the top and the bottom comprising the second outer wax layer4 and the attached first inner wax to layer 1 can then easily beseparated, and the cheese portion 5 is ready for consumption.

If the tear strip 2 has holes, the second outer wax layer 4 is appliedunder conditions which lead to a melting together of the first inner waxlayer 1 and the second outer wax layer 4 and the melting together alsotakes place through the hole of the tear strip 2, so that the tear strip2 is firmly fixed between the first inner and second outer wax layers 1,4, so that the tearing away of the tear strip 2 takes with it thecorresponding parts of the first inner wax layer 1 and the second outerway layer 4.

After detaching the top and bottom portions of the second outer waxlayer 4 to which the first inner wax layer 1 firmly adheres, the cheeseportion 5 is ready for consumption.

A similar embodiment is shown in a perspective view in FIGS. 2 a to 2 c.The tear strip 2 is fixed only to the two elongated aide walls of thecheese portion 5 covered with the first inner wax layer 1 but it has oneprotruding tear strip portion so that it can be opened by pulling thetear strip portion 3 towards and around the tip of the cheese portion 5.Then, the top and bottom portions of the outer wax layer 4 can be openedand the cheese portion 5 is ready for consumption.

A further preferred embodiment of the invention is shown in FIGS. 3 a to3 c. Here, the top and one side wall of the cheese portion 5 are coveredwith the tear strip 2 which, again, has in a preferred embodiment aplurality of holes 6 throughout and one protruding portion 3.

The situation after tearing away tear strip 2 is shown in FIG. 3 c. Thetop portion of the cheese portion 2 and one of the elongated side wallsare separated from the package and the cheese portion 5 can be taken outof the package and consumed.

The process for packaging cheese according to a preferred embodiment ofthe present invention will now be illustrated in more detail. Theprocess will be described with respect to process cheese. However, asmentioned above, the invention may be useful for any type of cheese.

As a separate first production step hot and liquid process cheese isfilled into casings and cooled down. These casings with process cheesecan be stored for several days before proceeding with the followingproduction steps.

After removal of the casing the firm process cheese sausage is cut intoslices (preferably round) and each slice is cut into portions 5(preferably six portions 5 that are generally triangularly shaped). Dueto this cutting operation the preferred triangle portion 5 consists of 2straight sides and 1 rounded side. After the cutting these cheeseportions 5 are placed separately on a conveyor belt. Automatically bytransporting on belts and rolls the portions pass a waxing station. Thewax is hot and liquid and will cover the portions 5 completely(preferably the wax is sprayed onto the top and bottom of the portion 5)with a thin first inner wax layer 1 which might be optionally colored.These production steps from the removal of the casing throughapplication of the first wax layer 1 are preferably conducted in a cleanroom environment. After these production steps it is possible to takeout the waxed process cheese portions and store the portions (preferablyunder refrigeration) for several days.

The following steps can be done without clean room conditions. Thepre-waxed process cheese portions, either from the storage or directlycoming out of the first waxing step, pass a label applicator which addsself-adhesive labels with or without holes onto the first inner waxlayer 1. Some options how to apply the label are set forth below. Otherlabel shapes and label positioning on the first inner layer wax 1 arepossible.

Option 1: the self adhesive label is a rectangular elongated tear strip2 with or without holes 6 which is applied onto the two sides of thefirst inner wax layer 1 with a protruding portion 3 (opening handle) onthe tip of the portion 5 (FIGS. 1 a-e).

Option 2: the self adhesive label is a rectangular elongated tear strip2 with or without holes 6 which is applied to the two long sides of thefirst inner wax layer 1 with a protruding portion 3 close to the roundside of the portion 5 (FIGS. 2 a-c).

Option 3: the self adhesive label, generally triangularly shaped with orwithout holes 6 is applied to the top side and to one of the long sidesof the first inner wax layer 1. The protruding portion 3 is positionedat a corner of the round side of the portion 5 (FIGS. 3 a-c).

After the label placement onto the process cheese portion, the portionautomatically by transporting on belts and rolls passes a second waxingstation. This wax is also hot and liquid and will cover the portionscompletely (preferably the wax is sprayed onto the top and bottom of theportion) with a thin second outer layer 4 which might be optionallycolored. The self adhesive label is designed such that a part of thelabel is a protruding portion 3 standing away from the process cheeseportion and this part is foreseen to be used as the opening handle.

After cooling each waxed process cheese portion can be further packed.Potential options of packing are wrapping, netting, flow packing orpacking into other packaging. The preferred option is wrapping into athin pre-printed plastic film with an automatic wrapping machine.

The present invention will now be illustrated by a specific examplewhich is not intended to limit the scope of the invention.

EXAMPLE

Process cheese is filled into sausage casings of approximately 1 meterlength and 98 mm diameter. After cooling, the sausage casing is removedand cheese slices with a thickness of approximately 14 mm are cut. Sixprocess cheese portions are cut out of each round slice with a diameterof 98 mm. The dimension of one generally triangular cheese portion 5equals a segment with a 49 mm radius, an angle of 60 degrees and aheight of 14 mm. The weight per triangle is approx. 20 g. The weight ofsix pieces is 120 g. Each triangle passes a wax bath (white wax, atabout 85° C.) where the first transparent inner wax layer 1 is added.This wax is a blend of hydrocarbon based waxes and plastics. Thetriangle portion 5 is moving forward on rolls and the wax is sprayedfrom the top and from the bottom side to ensure that it is completelycovered by wax. Approximately 1.5 grams of wax (about 0.1-0.2 mmthickness) is added. These operations are done in a clean room(according to class 10.000 US Fed. Standard 209 D).

The following operations are then done at “normal environmentalconditions”. After the wax bath the triangle portion 5 is cooled down totemperatures of about 20 degrees C. by passing a cooling cell (cold aircirculation). Each portion 5 is maintained (by belts) in a definedhorizontal direction on the conveyor belt. One side of the triangle isin the direction of the tear strip applicator. The tear strip applicator(standard equipment, PAGO company) applies a self adhesive tear strip 2which is made of polypropylene and coated with an adhesive layer. Therectangular tear strip 2 (preferred embodiment) contains holes 6(preferably round, but any other shape is possible). With the aid of theadhesive one side of the tear strip 2 is fixed on the inner wax layer 1.By passing a roll, the other side of the label is pressed onto the innerwax layer 1. The tear strip 2 is added according to FIG. 2 with oneprotruding portion 3 (opening handle). Each triangle then passes asecond wax bath (blue wax, about 75° C.) where a second outer wax layer4 is added. This wax is a blend of hydrocarbon based waxes, plastics andblue pigments. Approximately 3.0 grams of blue wax (about 0.2-0.4 mmthickness) is added. The portion 5 moves forward on rolls and the wax issprayed from the top and from the bottom to ensure that the portion iscompletely covered by wax. As the tear strip 2 contains holes the secondouter wax layer 4 is partially melting the first inner wax layer 1 inthe area of the holes. This results in good removal of the two waxlayers 1, 4 by pulling off the tear strip 2. After the wax bath thegenerally triangular portions 5 are kept refrigerated (at about 4° C.)before they will be ready for adding a secondary packaging (e.g., acellophane wrapper).

1. Wax-coated cheese, comprising: (a) a cheese portion; (b) a firstinner wax layer covering said cheese portion; (c) a second outer waxlayer covering said first inner wax layer; and (d) a tear strip betweensaid first inner and second outer wax layers covering selected parts ofsaid first inner wax layer and comprising at least one portion whichprotrudes from said first inner and second outer wax layers andcomprising an adhesive layer for adhering said tear strip to said firstinner wax layer.
 2. The wax-coated cheese according to claim 1, whereinsaid tear strip comprises a plurality of holes throughout, through whichsaid first inner and second outer wax layers are firmly connected. 3.The wax-coated cheese according to claim 2, wherein the cheese isprocessed cheese.
 4. The wax-coated cheese according to claim 3, whereinsaid first inner wax layer is uncolored.
 5. The wax-coated cheeseaccording to claim 4, wherein said second outer wax layer is colored. 6.The wax-coated cheese according to claim 5, wherein said cheese portionhas a generally triangular form.
 7. The wax-coated cheese according toclaim 6, wherein said tear strip is provided on three side walls of saidcheese portion and has one protruding portion.
 8. The wax-coated cheeseaccording to claim 6, wherein said tear strip is provided at twoelongated side walls of said cheese portion and has one protrudingportion.
 9. The wax-coated cheese according to claim 6, wherein saidtear strip is provided at two elongated side walls of said cheeseportion and has two protruding portions.
 10. The wax-coated cheeseaccording to claim 6, wherein the tear strip is provided at the top andat one elongated sidewall of the processed cheese portion and has oneprotruding portion.
 11. A packaging system for packaging a cheeseportion, comprising: (a) a first inner wax layer covering said cheeseportion; (b) a second outer wax layer covering said first inner waxlayer; and (c) a tear strip between said first inner and second outerwax layers covering selected parts of said first inner wax layers andcomprising at least one portion which protrudes from said first innerand second outer wax layers, and comprising an adhesive layer foradhering said tear strip to said first inner wax layer.
 12. Thepackaging system according to claim 11, wherein said tear stripcomprises a plurality of holes throughout, through which said firstinner and second outer wax layers are firmly connected.
 13. Thepackaging system according to claim 11 for packaging processed cheese.14. The packaging system according to claim 11, wherein said first innerwax layer is uncolored.
 15. The packaging system according to claim 14,wherein said outer wax layer is colored.
 16. The packaging systemaccording to claim 13, wherein said packaging system has a triangularform.
 17. The packaging system according to claim 16, wherein said tearstrip is provided on three side walls of processed cheese portion andhas one protruding portion.
 18. The packaging system according to claim13, wherein said tear strip is provided on two elongated side walls ofprocessed cheese portion and has one or two protruding portions.
 19. Thepackaging system according to claim 16, wherein said tear strip isprovided on the top and at one elongated side wall of processed cheeseportion and has one protruding portion.
 20. A process for packaging acheese portion, comprising the steps of: (a) providing a cheese portionwith a first inner wax layer; (b) placing a tear strip over selectedparts of said first inner wax layer, wherein said tear strip comprisesat least one portion which protrudes from said first inner wax layer andwherein said tear strip has an adhesive layer for adhering said tearstrip to said first inner wax layer; and (c) applying a second outer waxlayer onto said first inner wax layer and said tear strip.
 21. Theprocess according to claim 20, wherein said tear strip has a pluralityof holes throughout, and wherein step (c) is carried out underconditions which allow said first inner and second outer wax layers tomelt together and form a firm connection through said holes of said tearstrip.
 22. The process according to claim 21, wherein said cheeseportion is a processed cheese portion.
 23. The process according toclaim 20, wherein said first inner wax layer is uncolored.
 24. Theprocess according to claim 23, wherein said second outer wax layer iscolored.
 25. The process according to claim 22, wherein said processedcheese portion has a triangular form.
 26. The process according to claim25, wherein said tear strip is provided on three side walls of saidprocessed cheese portion and has one protruding portion.
 27. The processaccording to claim 25, wherein said tear strip is provided on twoelongated side walls of said processed cheese portion and has one or twoprotruding portions.
 28. The process according to claim 25, wherein saidtear strip is provided on the top and at one elongated side wall of theprocessed cheese portion and has one protruding portion.